CAT Pumps 7CP6111CS User manual

www.catpumps.com
Product Quality, Reliability and Support You Expect
SERVICE MANUAL
7CP STAINLESS STEEL PLUNGER PUMPS
PUMP MODELS INCLUDED
7CP6111CS 7CP6111CCS 7CP6111CSG1 7CP6171CS 7CP6171CCS

SERVICE MANUAL | 7CP Stainless Steel Series Plunger Pumps2(763) 780-5440 | [email protected] | www.catpumps.com
Safety Symbols 2
General Safety Information 3
Seal & Valve Kits 6
Service Intervals 6
Seal & Valve Kit Pump Diagram 7
Tools Needed 7
Servicing the Seals 8
Manifold and Seal Removal 8
Plunger Removal 10
Plunger Reassembly 11
Seal Installation 12
Manifold Reassembly 13
Servicing the Valves 14
Valve Removal 14
Valve Disassembly 14
Valve Reassembly 15
Valve Installation 16
Reference Information 17
Crankcase Component Inspection 17
Pump Rotation 18
Preventive Maintenance Schedule 18
Torque Chart 19
Manifold Screws Torque Sequences 19
Technical Bulletin Reference Chart 19
Diagnosis and Maintenance 20
Table of Contents
IMPORTANT SAFETY INSTRUCTIONS
It is the responsibility of the user to read and understand all
instructions, important safeguards and safety precautions before
operating or servicing any pump. Failure to do so may result in
property damage, personal injury or death.
GENERAL SAFETY INFORMATION AND SYMBOLS
Pay special attention to the following signal words, safety alert
symbols and statements:
Safety Symbols
Indicates a potential personal injury hazard.
Obey all safety messages that follow this
symbol to avoid possible injury or death.
Indicates a hazardous situation which, if not
avoided, could result in minor or moderate
injury or property damage.
Indicates a hazardous situation which, if not
avoided, could result in property damage.
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.

SERVICE MANUAL | 7CP Stainless Steel Series Plunger Pumps 3(763) 780-5440 | [email protected] | www.catpumps.com
General Safety Information
A. FLAMMABLE OR EXPLOSIVE LIQUID HAZARD
Do not operate pump with ammable or explosive liquids unless extraordinary safety precautions are observed. Leaks of ammable or explosive
liquids, if exposed to elevated temperatures, static electricity, sparks or other hazards, will result in ame or possible explosion, causing serious
personal injury, death or property damage.
1. Before operating pump with ammable or explosive liquids, ensure proper maintenance has been performed.
2. Do not operate pump with ammable or explosive liquids if leaks are detected.
3. Only pump ammable or explosive liquids that are compatible with pump component materials.
4. Do not operate pump with ammable or explosive liquids without safeguards or safety systems to detect leaks, elevated temperatures,
spark prevention or any other hazards dened by the NFPA systems.
5. Do not remove Flammable Liquids Product Suitability Hang Tag to assure proper safety.
6. Follow ATEX guidelines for potentially-explosive atmospheres.
A. ELECTRICAL SHOCK HAZARD
Do not service pump or electrical equipment while energized. Electricity can cause personal injury, death or property damage.
1. Adhere to “Lock Out” and “Tag Out” procedures for electrical equipment.
2. Before commencing pump service, turn power supply o.
3. Keep water away from electrical outlets and electrical devices.
4. Electrical components must be installed by a qualied electrician to avoid risk of electrocution.
B. ROTATING PARTS HAZARD
Do not service pump while energized. Moving, rotating or reciprocating parts can crush and cut, causing personal injury, death
or property damage.
1. Adhere to “Lock Out” and “Tag Out” procedures for electrical equipment.
2. Before commencing pump service, turn power supply o, turn water supply o, squeeze trigger on gun to relieve system pressure.
3. For mobile equipment, be sure engines and hydraulics are turned o and secured to avoid accidental start.
4. Do not operate with safety guards removed.
5. Always use safety guards on all belt drives, couplings and shafts.
C. HOT SURFACE HAZARD
Do not touch pump, accessories or drive system while operating and until cool down is complete. Touching hot surface areas of the pump,
accessories or drive system can cause severe burns or personal injury.
D. SKIN PUNCTURE HAZARD
Do not allow spray to contact any part of the body or animals. Pumped liquids under high pressure can pierce skin and underlying tissue
or can deect debris leading to serious personal injury or death.
1. Relieve all line pressure in the inlet line to the pump and discharge line from the pump before performing any maintenance on the pump.
2. When a high-pressure gun is not in use, set safety trigger lock (safety latch) to avoid accidental high-pressure operation and personal injury
or property damage.
3. Do not check for leaks with hand. Use a piece of cardboard to check for leaks.
4. Review cleaning procedures to minimize heavy back blasting.
5. Wear adequate safety equipment and clothing when operating a high-pressure sprayer. Never use high-pressure spray with bare feet or exposed
skin, and always wear safety glasses.
E. PUMPING LIQUIDS HAZARD
Do not operate pump with hot water, chemicals or other hazardous liquids unless extraordinary safety precautions are observed.
Pumping hot water, chemicals or other hazardous liquids can expose personnel to serious injury.
1. Provide guards or shields around equipment to protect personnel.
2. Wear mask, goggles or eye protection while operating high-pressure equipment.
3. Obtain a Safety Data Sheet (SDS) and take appropriate safety measures for the liquid being handled.

SERVICE MANUAL | 7CP Stainless Steel Series Plunger Pumps4(763) 780-5440 | [email protected] | www.catpumps.com
General Safety Information and Symbols
F. OVER PRESSURIZATION HAZARD
Do not operate high-pressure pumping system unless extraordinary safety precautions are observed. A high-pressure pumping system can
deadhead or over pressurize causing serious personal injury and property damage.
1. All high-pressure systems require a primary pressure regulating device (e.g., regulator or unloader) and a secondary pressure safety relief device
(e.g., pop-o valve, safety valve, rupture disc) to assure proper pressure setting and overpressure protection.
2. All high-pressure systems require a pressure gauge to monitor pressure settings and avoid overpressure of equipment or personal harm.
3. Install primary pressure relief device on the discharge side of the pump.
4. Install secondary pressure relief device between the primary device and pump.
5. Install pressure gauge onto the discharge manifold or in the discharge line near the manifold.
6. Open all valves on discharge side of plumbing before operation.
G. OXYGEN HAZARD
Do not charge pulsation dampeners with oxygen. Oxygen may cause an explosion causing personal injury, death or property damage.
1. Use nitrogen only when charging pulsation dampeners, DO NOT USE OXYGEN.
2. Use proper charging tools to charge pulsation dampeners.
3. Charge pulsation dampener within specications stated on data sheet to assure proper pulsation dampening and prevent failure of bladder.
H. FALL HAZARD
Do not operate pressure washer while standing on slippery or unstable surface unless extraordinary safety precautions are observed.
Pressure washing may create slippery surface on which a person may slip and fall causing personal injury or death.
1. Wear suitable footwear to maintain a good grip on wet surfaces.
2. Do not stand on ladders or scaolding.
3. Do not over reach or stand on unstable supports.
4. Keep good footing and balance and hold gun with both hands to control kick back.
A. IMPROPER USE OF FITTINGS HAZARD
Do not operate the pump with improperly-connected, sized, worn or loose ttings, pipes or hoses. Operating the pump under these conditions
could result in personal injury and property damage.
1. Ensure all ttings, pipes and hoses are properly rated for the maximum pressure rating and ow of the pump.
2. Check all ttings and pipes for cracks or damaged threads.
3. Check all hoses for cuts, wear, leaks, kinks or collapse before each use.
4. Ensure all connections are tight and secure.
5. Use PTFE thread tape or pipe thread sealant (sparingly) to reconnect plumbing. Do not wrap tape beyond the last thread, this will prevent loose
tape from becoming lodged in the pump or accessories.
6. Apply proper sealants to assure secure t or easy disassembly when servicing.
B. FROZEN LIQUID HAZARD
Do not operate the pump with frozen liquid. Operating the pump under this condition could over pressurize and jettison the manifold from
the crankcase causing personal injury and property damage.
1. Store pump or pumping system in an environmentally-controlled room protected from freezing temperatures.
2. Follow procedures in TECH BULLETIN 083 to winterize pump.
C. CLEANING PUMP HAZARD
Do not use solvents that are ammable and toxic to clean or degrease equipment. Use of these solvents could result in personal injury
and property damage.
1. Follow safety instructions as found in SDS or on packaging of each liquid.
2. Clean equipment in a well-ventilated area.
3. Disposal of solvents to be in accordance with local, state and federal regulations.
CONTINUED

SERVICE MANUAL | 7CP Stainless Steel Series Plunger Pumps 5(763) 780-5440 | [email protected] | www.catpumps.com
General Safety Information and Symbols
D. OPERATING BEYOND SPECIFICATIONS HAZARD
Do not operate the pump outside the specications of individual pump data sheet or service manual. Operating the pump under these
conditions could result in personal injury and property damage.
1. Do not operate the pump faster than the maximum recommended RPM.
2. Do not operate the pump at pressures higher than the maximum recommended pressure.
3. Do not operate the pump at temperatures higher than the maximum recommended temperatures.
4. Do not use accessories that are not compatible or rated for the pump.
E. LIFTING DEVICE HAZARD
Do not lift pump with unsuitable lifting devices. Use of unsuitable lifting devices may cause pump to fall, resulting in personal injury, damage
to pump and/or pump with drive/base plate.
1. Lifting eyes installed on the pump must be used only to lift the pump.
2. Special lifting eyes should be installed on the base for lifting the pumping system (e.g. base, drive and accessories)
3. If slings or chains are used for lifting, they must be safely and securely attached to properly balance the weight of the unit.
4. Inspect slings and chains prior to use and replace worn and damaged slings and chains.
A. OIL HAZARD
Use only genuine Cat Pumps custom-blend, premium-grade, petroleum-based hydraulic oil. Use of other oil may not provide proper
lubrication of drive-end components and may result in damage to the crankcase of the pump.
1. Fill pump crankcase to specic capacity indicated on data sheet or service manual prior to startup.
2. Cat Pumps premium custom-blend oil is available worldwide in 21-ounce bottles, (single and 12-pack cases), 2.5 gallon jugs (single and 2-pack)
or 30 gallon drums. Use of other oils may void the warranty.
B. PUMP ROTATION DIRECTION HAZARD
Do not rotate pump crankshaft in reverse direction. Rotation of pump crankshaft in reverse direction may not provide proper lubrication
and may result in damage to the drive-end components.
1. Forward rotation is the top of the crankshaft turning towards the manifold head of the pump.
2. Ensure oil is lled to the center red dot on sight gauge for forward rotation.
3. If reverse rotation is unavoidable, ensure oil is lled to slightly above center red dot on sight gauge.
C. BELT TENSION HAZARD
Do not operate pump with excessive belt tension. Excessive belt tension may damage the pump’s bearings or reduce horsepower.
1. Rotate pump crankshaft before starting to ensure shaft and bearings are moving freely.
2. Ensure pulleys are properly sized.
3. Periodically replace belts to assure full horsepower transmission.
4. Ensure center distance dimensions between pulleys is correct.
D. BYPASS OPERATION HAZARD
Do not operate the pump in bypass for extended lengths of time. Operating the pump under this condition can quickly cause heat build-up
resulting in damage to the pump.
1. Route bypass line to supply reservoir to dissipate heated bypass liquid into a large reservoir of cool water to reduce excessive temperature
build-up.
2. Route bypass line to inlet of pump using a thermo valve in the bypass line or auto shut-o assembly that will sense temperature rise
and either bypass or shut down system before damage occurs.
E. DRY OPERATION HAZARD
Do not operate the pump without water or liquid. Operating pump under these conditions could result in damage to the pump.
1. Open all valves on inlet side of pump before starting operation to prevent starving the pump.
2. Do not exceed inlet suction pressure limit specied in pump data sheet.
3. Ensure inlet feed exceeds the maximum ow being delivered by the pump.
4. Ensure all ttings, pipes and hoses are properly-sized for the pump to avoid restricted ow.
5. Review and implement all other recommendations appropriate for your system from the Inlet Condition Check-List.
CONTINUED